Alkylene oxides production from alkanes or alkylaromatics using molten nitrate salt catalyst

Abstract

A process for producing an alkylene oxide or mixture of alkylene oxides by a reaction which comprises reacting an alkane or alkylaromatic compound mixture thereof with an oxygen-containing gas in the presence of at least one molten nitrate salt catalyst.

What is claimed is: 
     
       1. A process for producing an alkylene oxide or mixture of alkylene oxides by a reaction which comprises reacting an alkane or alkylaromatic compound having from 3 to 22 carbon atoms per molecule, or mixture thereof, with an oxygen-containing gas, said alkane or alkylaromatic compound and said oxygen-containing gas being gaseous reactants, by contacting said gaseous reactants with a bath, stream, spray or mist of at least one molten nitrate salt catalyst, said catalyst being present in an amount sufficient to absorb any heat generated during said reaction while maintaining an essentially constant reaction temperature, said reaction being conducted at a reaction temperature of between about 135° C. and about 600° C. and a reaction pressure of between about 1 and about 50 atmospheres. 
     
     
       2. The process of claim 1 wherein said molten nitrate salt is selected from the group consisting of sodium, potassium, lithium, cesium, magnesium, and calcium molten nitrate salts and mixtures thereof. 
     
     
       3. A method for producing an alkylene oxide from an alkane or alkylaromatic compound having from 3 to 22 carbon atoms per molecule or mixture thereof, which comprises bubbling gaseous reactants consisting of an oxygen-containing gas and said alkane or alkylaromatic compound, or mixture thereof, through a bath of at least one molten nitrate salt catalyst, said catalyst being present in an amount sufficient to absorb any heat generated during said reaction while maintaining an essentially constant reaction temperature, said reaction being conducted at a reaction temperature of between about 135° C. and about 600° C. and a reaction pressure of between about 1 and about 50 atmospheres. 
     
     
       4. The method of claim 3 wherein said oxygen-containing gas is fed into said bath by means of a first tube and wherein said alkane or alkylaromatic compound, or mixture thereof, is fed into said bath by means of a second tube. 
     
     
       5. The method of claim 4 wherein said first tube and said second tube are co-axially mounted with respect to each other. 
     
     
       6. The method of claim 3 wherein said alkane or alkylaromatic, or mixture thereof, has between 3 and 15 carbon atoms per molecule on average. 
     
     
       7. A process for producing an alkylene oxide or mixture of alkylene oxides by a reaction which comprises reacting an alkane or alkylaromatic compound having from 3 to 8 carbon atoms per molecule, or mixture thereof, with an oxygen-containing gas, said alkane or alkylaromatic compound and said oxygen-containing gas being gaseous reactants, by contacting said gaseous reactants with a bath, stream, spray or mist of at least one molten nitrate salt catalyst, said catalyst being present in an amount sufficient to absorb any heat generated during said reaction while maintaining an essentially constant reaction temperature, said reaction being conducted at a reaction temperature of between about 135° C. and about 600° C. and a reaction pressure of between about 1 and about 50 atmospheres. 
     
     
       8. The process of claim 7 wherein said alkane or alkylaromatic compound has from 3 to 6 carbon atoms per molecule. 
     
     
       9. The process of claim 7 wherein said contacting of said gaseous reactants with said molten nitrate salt is effected by countercurrent flowing of said gaseous reactants into a stream, spray or mist of said molten nitrate salt.